TWI Digital Library

The CFD (computational fluid dynamics) technique was employed to develop a numerical model of friction stir welding (FSW) of DH36 steel (0.16%C, 1.2%Mn, 0.02%Cr, 0.02%Nb, 0.04%Al, 0.03%Cu) plate (thickness 6 mm) under low and high welding speed cond…

Dissimilar butt and lap joints between AA 5083-H111 or AA 6082-T6 aluminium alloys and copper were fabricated by friction stir welding and morphological, metallographic and structural analyses were undertaken on weldments made under a range of proce…

The effects of friction stir welding (FSW) tool geometry on material flow during the welding of 4 mm aluminium alloys 2024-T51 and 6056-T4 were investigated. Welds were made using three different welding tool pins (conical non-threaded profile, coni…

An abrasion circle friction stir spot welding (ABC-FSSW) technique was employed to fabricate dissimilar metal joints between aluminium and steel automotive sheets, and the microstructure, mechanical properties and weld formation mechanisms of the jo…

This study addresses the challenges of predicting joint efficiency for friction stir welding (FSW). It adopts a data driven approach, leveraging data analytics to develop accurate predictive models. A database of 1780 records from diverse aluminium …

Flame resistant AZX 612 (Mg, 6%Al, 1%Zn, 2%Ca) magnesium alloy joints were fabricated by asymmetric double sided friction stir welding (FSW) and the influence of tool rotational speed on their microstructure and mechanical properties was investigate…

Similar overlap and dissimilar butt joints were fabricated by friction stir spot joining of AA 6061-T6 (Al, 1-1.1%Mg, 0.66-0.67%Si) and AA 5052-H34 (Al, 2.58%Mg) sheets of thickness 1 and 2 mm, respectively, and microstructural analysis was used to …

An experimental investigation was undertaken into the preparation and mechanical properties of two candidate substitutes to MP 159 Ni-Co alloy as tool materials for friction stir welding of high strength aluminium alloys. The alloys studied were "Ae…

In relation to the development of friction stir welding (FSW) technology for railway rolling stock manufacture in China, an investigation is presented into the microstructure and mechanical properties of AA 6005A-T6 aluminium alloy (Al, 0.56%Mg, 0.7…

Stationary shoulder friction stir welding (SSFSW) and conventional FSW experiments were undertaken on AA 7050-T7651 alloy plates (thickness 6.3 mm) to demonstrate the advantages of SSFSW with respect to surface finish, thermal profile symmetry, HAZ …

Defects and their mitigation associated with the fabrication of fluid-cooled aluminium alloy heatsinks for electronic applications are discussed. The heatsink consisted of an aluminium alloy 6063 substrate (310 x 300 mm) with a series of rectangular…

The incorporation of strips of copper foil in friction stir welded aluminium alloy plate was evaluated for flow visualisation without disturbing the welding process. The strips, of 0.1 mm thickness, were placed in various longitudinal and transverse…

Arcan tests (pure tensile, pure shear and mixed tensile/shear loads) were performed on parent material (6056-T78 aluminium alloy) and friction stir welded (FSW) specimens for comparison purposes and to assess the capability of strain field measureme…

Aluminium alloy fusion welds were modified by friction stir processing (FSP) as a function of FSP location and tool design, and differences between the FSP locations and tools were quantified by microstructure and mechanical property measurements (u…

The friction stir weldability of the dissimilar materials copper and aluminium alloy was studied, assessing the effects of different process parameters (rotation and traverse speeds, rotation direction (Cu or Al on advancing side), displacement and …

A report is presented into the development of a refill friction stir spot welding (FSSW) robot system, performance evaluation with respect to FSSW of aircraft aluminium alloys, and fabrication of full-scale aircraft production components. The FSSW r…

The results of a programme to establish self reacting friction stir welding for thin gauge (less than 3 mm) aluminium alloy applications are reported divided into the five major phases: tool development; joint evaluation; strength optimisation; prot…

An economic analysis was undertaken to compare the costs of onshore and offshore pipeline construction scenarios for welds made using friction stir welding (FSW) and conventional mechanised MIG/MAG welding. Pipe diameters of 1067 and 305 mm were sel…

A two-step modelling procedure, consisting of a thermo-fluid model and a thermo-mechanical model, was employed to predict temperature, flow and residual stress fields around the workpiece block, steel backing plate and tool in friction stir welding …

A thermal-pseudo-mechanical model, based on the use of material temperature-dependent yield stress as the driver for heat input, was proposed for heat generation in friction stir welding, and simulation results were compared with experimental temper…